KX250 shift shaft replacement

YamiLionheart · March 13th, 2013, 09:33 PM

I know this is not a ninja, but the bike is still a kawi, and a 250 cc engine!

The splines on the shift shaft are stripped to the point that the shift lever can no longer grip and turn the shaft, and thus, no longer shift the transmission.

Does anyone know of a good how to video/step by step guide on replacing the shift shaft on this bike or similar? It's something I'd like to try myself but want to know what I'm getting myself into.

thumper64 · March 13th, 2013, 09:36 PM

If I couldn't get the piece to fit on the splined shaft of the motor, I would either find a second one of those little brackets and weld it on, or grind the piece down square and make a new bracket. Or, maybe cut a keyway into the shaft and put a key in the bracket.

Another guy on this forum had a bike that had a rounded shaft and the shifter just would not grip it. He ended up just welding it.

alex.s · March 13th, 2013, 09:37 PM

you are talking about the external shift shaft and links. you take off the clutch cover and clutch and the rod slides out the right side. but you shouldn't really need to replace it. just repair the end. its not exactly high precision

thumper64 · March 13th, 2013, 09:39 PM

So how would you repair the end? Trace the splines with a little cutoff wheel on a Dremel tool?

YamiLionheart · March 13th, 2013, 10:06 PM

Quote:

Originally Posted by thumper64

If I couldn't get the piece to fit on the splined shaft of the motor, I would either find a second one of those little brackets and weld it on, or grind the piece down square and make a new bracket. Or, maybe cut a keyway into the shaft and put a key in the bracket.

Another guy on this forum had a bike that had a rounded shaft and the shifter just would not grip it. He ended up just welding it.

I already bought a replacement so I'd like to use it. But those options would probably be simpler.

Not sure how I would go about welding it, I did at one point attempt to do a half assed job with some JB weld which simply did not hold at all. Drilling straight through the shaft and lever and just bolting the two together could work. The bike is old and beat up anyway, doesn't have to be a clean job.

Motofool · March 14th, 2013, 06:00 AM

Quote:

Originally Posted by YamiLionheart

......Does anyone know of a good how to video/step by step guide on replacing the shift shaft on this bike or similar? It's something I'd like to try myself but want to know what I'm getting myself into.

http://www.xrv.org.uk/forums/xr/3194...ines-worn.html

old3 · March 17th, 2013, 10:55 AM

I raced a full season + on a 88 CR125 with a steel shifter welded to the stripped shaft. It was a $5 weld at a local shop. Clean it up free of oil, grease, paint & dirt. Should take all of 10 seconds to weld it on. If it has to come apart, you grind off the weld, the shaft is shot anyway. We took it off and welded it back on to swap a leaky seal. No big deal.

March 13th, 2013, 09:33 PM	#1
YamiLionheart ninjette.org member Name: Mike Location: Eastern LI, NY Join Date: Jan 2013 Motorcycle(s): 2009 Kawasaki Ninja 250R Posts: 166	KX250 shift shaft replacement I know this is not a ninja, but the bike is still a kawi, and a 250 cc engine! The splines on the shift shaft are stripped to the point that the shift lever can no longer grip and turn the shaft, and thus, no longer shift the transmission. Does anyone know of a good how to video/step by step guide on replacing the shift shaft on this bike or similar? It's something I'd like to try myself but want to know what I'm getting myself into.

March 13th, 2013, 09:36 PM	#2
thumper64 ninjette.org member Name: Tim Location: Quad Cities Join Date: Sep 2012 Motorcycle(s): Ninja 250 Posts: 102	If I couldn't get the piece to fit on the splined shaft of the motor, I would either find a second one of those little brackets and weld it on, or grind the piece down square and make a new bracket. Or, maybe cut a keyway into the shaft and put a key in the bracket. Another guy on this forum had a bike that had a rounded shaft and the shifter just would not grip it. He ended up just welding it. __________________________________________________ Motorcycle noob, feel free to ignore me.

March 13th, 2013, 09:37 PM	#3
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	you are talking about the external shift shaft and links. you take off the clutch cover and clutch and the rod slides out the right side. but you shouldn't really need to replace it. just repair the end. its not exactly high precision __________________________________________________

March 13th, 2013, 09:39 PM	#4
thumper64 ninjette.org member Name: Tim Location: Quad Cities Join Date: Sep 2012 Motorcycle(s): Ninja 250 Posts: 102	So how would you repair the end? Trace the splines with a little cutoff wheel on a Dremel tool? __________________________________________________ Motorcycle noob, feel free to ignore me.

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March 17th, 2013, 10:55 AM	#7
old3 ninjette.org sage Name: Jim Location: NJ Join Date: Nov 2012 Motorcycle(s): Ninja 300, KTM EXC610SMR Posts: 913	I raced a full season + on a 88 CR125 with a steel shifter welded to the stripped shaft. It was a $5 weld at a local shop. Clean it up free of oil, grease, paint & dirt. Should take all of 10 seconds to weld it on. If it has to come apart, you grind off the weld, the shaft is shot anyway. We took it off and welded it back on to swap a leaky seal. No big deal.